Related Manuals for Fronius Welducation Simulator
Summary of Contents for Fronius Welducation Simulator
- Page 1 Operating Instructions Welducation Simulator Welducation Campus EN-US Operating instructions 42,0426,0444,EA 007-17032025...
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Page 3: Table Of Contents
Product concept Visualization Scope of functions and supply Notes on the device Product updates Operating controls and connections Operating controls, indicators, and connections on the Welducation Simulator Installation Defaults Network settings Operating mode factory settings Before installation and initial operation... - Page 4 Connecting external displays Table stand Positions and setting options Magnet holder (optional) Safety Function Stand (optional) Safety Scope of supply and assembly Positions and setting options Operation Operation Plugging in the mains cable and switching on the device Operation Welding process Preparation Preparation Laying the hosepacks correctly...
- Page 5 Completing a course Course overview Virtual welding job Settings and results Starting a job Connecting to an available Welducation Simulator Welding job with the XR headset Simulation settings Welding parameters Carrying out welding on the workpiece Ending welding and assessment...
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Page 7: Safety
Safety... -
Page 9: Safety
Safety Explanation of DANGER! safety instruc- tions Indicates an immediate danger ▶ Death or serious injury will result if appropriate precautions are not taken. WARNING! Indicates a potentially dangerous situation ▶ Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a potentially harmful situation ▶... -
Page 10: Environmental Conditions
Environmental Operation or storage of the device outside the stipulated area will be deemed as conditions not in accordance with the intended purpose. The manufacturer accepts no liab- ility for any damage resulting from improper use. Installation and operation may only take place within closed and dry rooms. Temperature range of ambient air: During operation: -10°C to +40°C (+14°F to +104°F) During transport and storage: -20 °C to +55 °C (-4 °F to +131 °F) -
Page 11: Danger From Mains Current
Danger from An electric shock can be fatal. mains current All cables and leads must be secured, undamaged, insulated, and adequately di- mensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately. Do not wrap cables or leads around your body or parts of the body. Only trained and qualified personnel may carry out repair work (e.g., open the device). -
Page 12: Explanation For Canadian Industry
d) Anti-interference measures Shield other devices in the vicinity. Place the device far away from the affected receiver. Turn the device away from the affected receiver. Adjust the antenna of the affected receiver. Connect the device to another AC socket so that the device and the af- fected receiver use different circuits. -
Page 13: Particular Hazard Areas
NOTE! There is a possibility of electromagnetic interference due to incorrect use of the device. Impaired radio reception may result. ▶ The device for operation in the 5150-5250 MHz frequency band is only in- tended for use within closed and dry rooms, in order to reduce the poten- tial for radio interference from co-channel satellite mobile systems. -
Page 14: Safety Measures In Normal Operation
(e.g., relevant product standards of the EN 60 974 series). Fronius International GmbH hereby declares that the radio system of type Wel- ducation Simulator complies with Directive 2014/53/EU. The full text of the EU Declaration of Conformity is available on the following website: http://www.fronius.com... -
Page 15: General Information
General information... -
Page 17: Important Notes About This Document
Purpose of the These operating instructions describe the functionality, installation, operation, document and maintenance of the Welducation Simulator and the Welducation Campus software. This document is intended for use by all authorized persons who use the Weldu- cation training concept for teaching or learning welding. The training concept consists of the Welducation Simulator and the Welducation Campus software. -
Page 18: Functional Principle
Welducation Simu- lator. The Welducation Campus software is intended for external end devices, such as the supplied Fronius tablet or smartphones, notebooks, and PCs. It is possible for the trainers to put together a training program tailored to the needs of the trainees. -
Page 19: User Concept
User concept Target group The training concept, consisting of the Welducation Campus software and the Welducation Simulators, is aimed at all authorized teachers and trainees who are involved in teaching or learning the three welding processes MIG/MAG, TIG, and MMA. Another target group is administrators of the Welducation Campus soft- ware. -
Page 20: Utilization In Accordance With "Intended Purpose
All system components that are used in connection with the training concept are only suitable for training purposes and are not intended for real welding. Make sure that the Welducation Simulator and all components connected to it are only ever used within their permitted operating range. -
Page 21: Welducation Campus Software
XR headset. ▶ Read and follow all safety instructions in the operating instructions for the Welducation Simulator and the Welducation Campus software. Software up- As a result of updates, your software may contain functions that are not de- dates scribed in these operating instructions. - Page 22 USB thumb drive on the USB port of the Welducation Simulator. If no automatic software update is pre-configured, or in the case of a software update via USB thumb drive, the current firmware update can be found in the DownloadCenter for the Welducation Simulator welding technology product in question.
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Page 23: Welducation Simulator Training Concept
Workpieces XR headset Welding torch or electrode holder Product concept The Welducation Simulator allows trainees to learn welding skills in a realistic en- vironment, resulting in the following advantages: Low-cost training. Consumables are not required (wire electrodes, shielding gas, etc.). -
Page 24: Visualization
Scope of func- The standard equipment of the Welducation Simulator offers a wide range of tions and supply welding scenarios. In addition to the MIG/MAG, TIG, and MMA welding pro- cesses that can be learned with the simulator, the variety of supplied virtual workpieces ensures the trainees receive varied, practical training. - Page 25 Fronius tablet with case Operation of the Welducation Sim- ulator and the Welducation Cam- pus software XR headset Optical camera: for producing a real image of the environment Tracking camera: for displaying the virtual training view in the real image...
- Page 26 Simulation of common welding processes by means of the following components: MIG/MAG welding torch TIG welding torch and filler metal Electrode holder and stick elec- trode for manual metal arc weld-...
- Page 27 Realistic set-up for the preparatory tasks: All connections and cable connec- tions are faithfully reproduced. Thus, the return lead cable with workpiece clamp is also present.
- Page 28 Workpieces: T-joint, fillet weld Corner weld Lap joint...
- Page 29 Butt weld Square butt weld Y-butt weld Overlay welding Pipe connection Pipe-to-plate connection Diameter 80 mm T-joint, fillet weld Pipe-to-pipe connection Square butt weld Y-butt weld The following workpiece properties can be simulated: Materials: Steel Chrome-nickel Aluminum Common workpiece thicknesses, such as: 3 mm 6 mm 10 mm...
- Page 30 External visualization: Possible to connect to the Welducation Simulator for additional external dis- plays, such as projectors or monitors Storage tray: Positioned on the top of the Wel- ducation Simulator...
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Page 31: Notes On The Device
Notes on the Warning notices and safety symbols are located on the device. Removing or device painting over the warning notices and safety symbols is not permitted. They warn against incorrect operation. Safety symbols: Dispose of defective devices in accordance with safety rules and not in normal domestic waste. -
Page 32: Product Updates
Devices with the FCC label conform to the limit values for a Class B di- gital device, pursuant to Part 15 of the FCC regulations. This device conforms to the limit values for a Class B digital device, pur- suant to Part 15 of the FCC regulations. These limit values are designed to provide reasonable protection against harmful interference in a resid- ential installation. -
Page 33: Operating Controls And Connections
Operating controls and connections Operating con- Ventilation openings: trols, indicators, Device cooling and connections on the Welduca- MIG/MAG welding torch con- tion Simulator nection: For connecting the MIG/MAG welding torch Storage tray: e.g., for storing the XR headset and interaction target Holder for the welding torch or electrode holder Front... - Page 34 (11) USB port: To charge a tablet To export data Service interface Rear (12) Power switch: To switch the Welducation Simulator on and off (13) WiFi antenna (14) Mains cable connection (15) Knurled screw To secure the MIG/MAG weld- ing torch...
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Page 35: Installation
Installation... -
Page 37: Defaults
Defaults Network settings Necessary network settings must be made by IT administrators, for example, in a company network. Detailed information can be found in the section Cloud commissioning. Operating mode The default delivery state is always Offline Standalone. factory settings Online Cloud must be set up separately. -
Page 38: Before Installation And Initial Operation
Possibility of devices or system components toppling or falling This can result in minor injury and damage to property. ▶ Set up the Welducation Simulator, the stands, and all system components in a stable position. ▶ Ensure the interaction target and virtual workpieces are held securely in place. -
Page 39: Waiting Time Until The Power Connection Is Established
The technical data on the rating plate applies. Installing sys- Position the storage tray on top of the Welducation Simulator and attach it to tem components the handle tube. If desired, hang the welding torch or electrode holder in the designated hold- er on the storage tray. -
Page 40: Connecting Lan
Connecting LAN Before switching on the Welducation Simulator: Connect LAN to the network con- nection (9). Rear Connecting ex- Before switching on the Welducation ternal displays Simulator: If necessary, connect external dis- plays such as projectors or monit- ors to the HDMI port (10) and switch on. -
Page 41: Positions And Setting Options
Table stand Positions and CAUTION! setting options Possibility of objects falling or toppling Toppling or falling objects may cause minor injuries and damage to property. ▶ Choose a load-bearing and level table / surface on which to set up the ta- ble stand. -
Page 42: Magnet Holder (Optional)
Magnet holder (optional) Safety CAUTION! Possibility of objects falling or toppling Toppling or falling objects may cause minor injuries and damage to property. ▶ When positioning the workpiece on the magnetic holder, ensure that the workpiece rests flush against the magnet. Function Used to secure the virtual workpiece to the stand for the optional Basic welding table... -
Page 43: Stand (Optional)
Stand (optional) Safety CAUTION! Possibility of objects falling or toppling Toppling or falling objects may cause minor injuries and damage to property. ▶ Choose a load-bearing and level surface on which to set up the stand. ▶ Set up the stand in such a way that it is held securely and cannot topple or fall down. -
Page 44: Positions And Setting Options
Positions and The stand comes complete with a magnetic holder. The workpiece is held mag- setting options netically on the magnetic holder of the stand. The terminal clamp for the return lead cable is attached in a suitable place on the stand. The stand offers the following positions and setting options: Rotate Swivel... -
Page 45: Operation
Operation... -
Page 47: Operation
The device may remain inoperative after being switched on or may fail during operation. ▶ When connecting the mains cable to the Welducation Simulator as ex- plained below, make sure that the mains cable audibly clicks into place at the connection on the Welducation Simulator. -
Page 48: Operation
Operation The Welducation Simulator is operated via the Welducation Campus software. This also applies to the settings listed below for the respective welding pro- cesses. Information on this can be found in the following chapters. -
Page 49: Welding Process
Welding process... -
Page 51: Preparation
Selecting the welding processes Selecting and setting the welding parameters The display of the amount of shielding gas set by means of the knob on the Welducation Simulator CAUTION! Possibility of objects falling or toppling Toppling or falling objects may cause minor injuries and damage to property. -
Page 52: Laying The Hosepacks Correctly
Laying the hosepacks cor- rectly... -
Page 53: Mig/Mag
MIG/MAG MIG/MAG weld- ing commission- Open the cover on the Welducation Simulator. NOTE! Possibility of the welding torch being only partially inserted This can result in damage to property. ▶ After inserting the welding torch, ensure it is in the correct limit position. - Page 54 Tighten the knurled screw for the welding torch to 3 Nm, using a TORX® screwdriver TX25. Close the cover on the Welducation Simulator. Insert the return lead cable into the (-) current socket and lock Switch on the tablet.
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Page 55: Description Of Mig/Mag Operating Modes
Description of MIG/MAG Operating Modes 2-step mode 4-step mode... -
Page 56: Special 4-Step Mode
Special 4-step mode "Special 4-step mode" takes into account the high thermal conductivity of alu- minum and is suitable for welding aluminum materials. Symbols and ab- breviations Press the torch trigger | Hold the torch trigger | Release the torch trigger Gas pre-flow time Starting-current phase: rapid heating of the base material despite high heat dis- sipation at the start of welding... - Page 57 Final current duration End arc length correction parameter: Arc length correction at the end of welding Slope 2: continuous reduction of the welding current to the final current Gas post-flow...
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Page 58: Mig/Mag Standard Manual Welding
If required, set the dynamic parameter to influence the short-circuiting dy- namic at the instant of droplet transfer Set the required amount of shield- ing gas by means of the knob on the Welducation Simulator. The Welducation Simulator is ready. -
Page 59: Mig/Mag Synergic Welding
Pulse correction, for correcting the pulse energy in the pulsed arc Set the required amount of shield- ing gas by means of the knob on the Welducation Simulator. The Welducation Simulator is ready. -
Page 60: Tig
TIG welding commissioning Connect the control plug of the TIG welding torch to the torch control con- nection and lock it. Insert the bayonet connector of the TIG welding torch into the (-) current socket and turn it clockwise to lock. Insert the return lead cable into the (+) current socket and lock. - Page 61 Set the required amount of shield- ing gas by means of the knob on the Welducation Simulator. The Welducation Simulator is ready.
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Page 62: Description Of Tig Operating Modes
Description of TIG Operating Modes Symbols and ex- planations (1) Pull back the torch trigger and hold it in this position. (2) Release the torch trigger. (3) Briefly pull back the torch trigger (< 0.5 s). (4) Push the torch trigger forwards and hold it in this position. (5) Release the torch trigger. - Page 63 DOWN 4-step mode *) Intermediate lowering With intermediate lowering, the welding current is lowered to the set lowering current I-2 during the main current phase. To activate intermediate lowering, push the torch trigger forwards and hold it in this position. Release the torch trigger to resume the main current.
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Page 64: Rod Electrode
(+) or (-) welding can be found on the stick electrode packaging. With the Welducation Simulator, the supplied stick electrode can be used for all available scenarios on (+) and (-). Depending on the type of electrode, insert the return lead cable into the (-) current socket or into the (+) current socket and turn it clockwise to lock. - Page 65 Place the stand securely on the ta- ble / surface. Fix the workpiece in the desired welding position using the stand. Attach the terminal clamp for the return lead cable in a suitable place on the stand. The Welducation Simulator is ready.
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Page 67: Software
Software... -
Page 69: Welducation Platform
Welducation AdminTool intended for managing devices and users Both applications can be used with the supplied Fronius tablet. Other end devices (smartphones, notebooks, PCs, etc.) are possible for the "Cloud" operat- ing mode. Only use the Fronius tablet for "Standalone" operating mode. -
Page 70: Operating Modes
Welducation Simulators independently of location (manage courses/ content, complete courses—e.g., theory). Changing oper- If, for example, the Welducation Simulator that is switched on does not appear in ating mode the Welducation Campus software, the welding torch can be used to indicate and switch the current operating mode. - Page 71 Once the desired operating mode is selected, confirm it using the torch trig- ger on the underside of the welding torch. The corresponding LED initially lights up orange and should change to green while the torch trigger is depressed. The Welducation Simulator performs a restart. The operating mode has been switched.
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Page 72: User Roles On The Welducation Platform
The Campus Students use the Welducation Campus software to complete the courses within the assigned organization. The Campus Students study the theory content already included or prepared by the trainer and complete the practical exercises assigned to them on the Welducation Simulator. - Page 73 Puts together the training program con- tents comprising theory and exercises Overview of the learning progress of the Campus Students Evaluates and assesses the Campus Stu- dents Initiates any calibration required Campus Complete the courses Students Complete the practical exercises on the Welducation Simulator Register...
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Page 74: Administrator Commissioning
Network name: Serial number of the Welducation Simulator Password: Serial number of the Welducation Simulator The following steps are required to access the Fronius tablet for the first time: For the first time, log in to the Wel- ducation Simulator with the follow-... -
Page 75: Campus Student" Login
The students now have to register themselves as well. After that, the trainer can assign courses to the registered students. Cloud commis- A Fronius tablet is not required for commissioning the "Cloud" operating mode. sioning The Welducation Simulator must be switched on. -
Page 76: Trainer Login
Switch to the AdminTool. Call up the device management and select the connected Weldu- cation Simulator. The following status indicators are possible for the Welducation Simulator: "FREE": The Simulator is available. "OFFLINE": The Simulator cannot be reached and is not available for welding jobs. -
Page 77: Campus Student" Login
Call up the following website: https://campus.welducation.com Perform registration, with verifica- tion of the specified e-mail ad- dress. Complete the login process in the software and accept the invitation to the organization. IMPORTANT: Each self-registered user is initially assigned the role of "Campus Student". -
Page 79: Using The Welducation Campus Software
Using the Welducation Campus software... -
Page 81: Courses
Courses Adding a course In the "Courses" menu, select "+Add" at the top right. The timing and content of planned courses can be adjusted prior to the start of the course. The end date can be adjusted for ongoing courses. No action can be taken for past courses. -
Page 82: Creating Learning Content
Virtual welding jobs can be found in the course overview under the heading of the corresponding welding process, e.g. "MAG". Virtual welding jobs are practical exercises that the student carries out on the Welducation Simulator. Settings and res- Select the "Settings" or "Results" tab in the respective course. -
Page 83: Connecting To An Available Welducation Simulator
Connecting to an In the symbol for an available Welducation Simulator: available Weldu- Select the "CONNECT" button. cation Simulator Wait for connection to be established: The message "STARTING" appears while the connection is being established. Once the connection is made: Check off the items in the checklist and configure the welding parameters. -
Page 84: Welding Job With The Xr Headset
Note: The details of the welding job can be viewed under WPS. WPS stands for "Welding Parameter Settings": Welding parameter settings Welding job with The interaction target (PUK) interacts the XR headset with the welding torch for the follow- ing actions: Changing welding parameters or similar Welding machine settings... -
Page 85: Simulation Settings
Simulation set- tings Darkening: simulates different darkening levels of the welding helmet Filter: offers the option of different environmental filters for better perception of the virtual objects Resolution: allows you to adjust the resolution Note: This setting affects the image quality; for example, increased image sharpness results in a greater delay. -
Page 86: Ending Welding And Assessment
Remove the XR headset and continue with the course depending on your per- sonal progress. Note: The user remains connected for a certain period. After an extended period of inactivity, the Welducation Simulator is disconnected automatically. Manual disconnection: Select the disconnect icon in the header. -
Page 88: Campus Students
Campus Students Adding a "Cam- The following preconditions must be met: pus Student" Self-registration of the "Campus Student" Accepted invitation (Cloud variant only, with Standalone the "Campus Stu- dent" is simply required to register themselves) Otherwise, the trainer has no way to assign the students to a course. The trainer adds a "Campus Student"... -
Page 89: Course Options And Content
Course options and content Course tem- "Course Template" is used as a template for courses. This allows continued use of plates existing course content, whereby only the new participants and the new course date are to be selected. To create a new template: Select "+ Add"... -
Page 90: Virtual Welding Jobs
Virtual welding The virtual welding jobs are used to jobs learn welding skills, such as: Welding machine preparation Welding machine settings Manual dexterity when welding Select the "virtual training" button. When selecting virtual training, a de- tailed description of the respective weld seam profile is provided. -
Page 91: Knowledge Check
"Hard": There is no checklist for preparing to weld. Impermissible use of the welding torch is possible. Ghosts are not visible. The workpiece may not be in an impermissible position. The welding machine settings must be configured by the user. All criteria are used to prepare for welding in the real world. -
Page 92: Calibration
Carry out the calibration using the provided calibration target, as follows: In the "Devices" menu, click on the icon with the 3 dots to switch to "Calibra- tion" for the corresponding Welducation Simulator. Position the calibration target in the same position as you position the work- piece afterwards. -
Page 93: Demo
Demo Demo Th "Demo" menu contains ready-made learning content and exercises for presentation or to get a quick overview of the course structure. -
Page 94: Device Management
Device Management Requirements The following prerequisites apply to the "Device Management" actions explained below: "Device Management" menu Only possible in Welducation AdminTool Only in Standalone ("OFFLINE") operating mode Factory reset For a factory reset, the "Reset Device" action deletes all data in the system and resets the system to the factory settings. -
Page 95: Troubleshooting, Maintenance, And Disposal
Troubleshooting, maintenance, and disposal... -
Page 97: Troubleshooting
Troubleshooting General If an error occurs in the operation of Welducation Simulator and Software Cam- pus, first try to resolve the problem as follows: Restart the Admin Tool or Welducation Campus depending on the applica- tion. Find possible updates in the Welducation AdminTool. -
Page 98: Troubleshooting
Troubleshooting The device is not working. The power switch is on, the status indicators remain dark, the device fan remains still. Cause: The mains lead is disconnected, the mains plug is not plugged in. Remedy: Check the mains lead and insert the mains plug if necessary. Cause: The mains cable is not properly locked in place at the Welducation Simulator connection. - Page 99 Repair or replace the tracking camera. If the tracking camera is defective, contact Fronius Support. The XR headset is not working. Cause: The XR headset is not connected to the Welducation Simulator. Remedy: Replace the XR headset connection cable. Cause: The XR headset is defective.
- Page 100 The Welducation Simulator signals a fault on the lower of the 3 LEDs (orange). Cause: Software error Remedy: If the error persists after restarting several times and (waiting for a few minutes between attempts), contact Fronius Support. Cause: Hardware error Remedy: Check all cables and connections.
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Page 101: Maintenance And Disposal
Maintenance and disposal Safety WARNING! Danger from incorrect operation and work that is not carried out properly This can result in severe personal injury and damage to property. ▶ Only trained personnel are permitted to perform the work and functions described in this document, in accordance with the applicable national and international standards. -
Page 102: Technical Data
Using the de- This radio transmitter (IC: 6158A-EQ261ACNIBT / Model: WPEQ-261ACNI(BT)) tachable an- has been approved by ISED for operation with the antenna type used at the spe- tenna cified maximum allowable gain. XR-Headset Mains voltage Supply via Welducation Simulator... -
Page 103: Standards
EMC emission class Mark of conformity CE, CSA Ambient air temperature range during operation -10°C to +40°C (+14°F to +104°F) during transport and storage -20°C to +55°C (-4°F to +131°F) Relative humidity up to 50% at +40 °C (+104 °F), non-condensing up to 90% at +20 °C (+68 °F), non-condensing... -
Page 104: Interactive Operating Instructions
Interactive operating instructions HTML5 operat- Interactive HTML5 operating instruc- ing instructions tions are available on the Fronius web- site for Welducation Simulator and Welducation Campus: https://manuals.fronius.com/html/ 4204260444...
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